Process for preconditioning air for use in the oxidation of hydrocarbon fuels



Sept. 12, 1961 H. LUNDY ET AL PROCESS FOR PRECONDITIONING AIR FOR USE IN THE OXIDATION OF HYDROCARBON FUELS 2 Sheets-Sheet 1 Filed March 28, 1960 OOOOO JAMES h. L u/vor HERMAN a. REMPEL RALPH SLA v/cH /N VE N 7' 095 HUEBNER & WORREL ATTORNEYS J. H. LUNDY ET AL PROCESS FOR PRECONDITIONING AIR FOR USE IN Sept. 12, 1961 THE OXIDATION OF HYDROCARBON FUELS 2 Sheets-Sheet 2 Filed March 28, 1960 O 8 I 8 8 5 6 m 6 6 7 m m. 7 7 M H 0 0 0O 0O RALPH SLAV/CH V1. 05 P MM R e S N A MW J INVENTORS HUEBNER 8 WORREL Sitaes The present invention relates to a process for preconditioning air for use in the oxidation of hydrocarbon fuels and more particularly to such a process having special application to the preconditioning of air for use in internal. combustion engines.

' The broad essence of the present invention resides in the discovery that copper oxide is an effective catalyst in'the oxidation of hydrocarbon fuels and more particu larlyin the discovery that the combustion of hydrocarbon fuels in internal combustion engines can be facilitated by'the admixture of minute quantities of cupric salts resulting from the interaction of solid acids or acid producing solid salts with copper in the air supply delivered to the combustion chambers of such engines.

The inefiiciencies of internal combustion engines are well known and result in the three primarily objectionable results. The economy of operation is less than desired. The accumulation of. partially burned and unburned fuel in'such engines impairs operation and shortens useful engine life. The exhausts from such engines contain air polluting constituents which are believed to be aprimary cause of the smog in areas of heavy traffic. The present invention is a further development of that disclosed in United States Patent No. 2,695,680 and is likewise directed to the improvement of the efficiencyof combustion-of hydrocarbon fuels in internal combustion engines.

Another object is to improve the overall efficiency of internal combustion engines.

.Another. object is to minimize the accumulation. of hard carbon in the combustion chambers and associated parts-of internal combustion engines.

Another object is to minimize creation or aggravation of smog.by internal combustion engines.

Another object is to reduce the carbon monoxide in the exhaust from internal combustion engines.

Another object is to minimize the discharge of nitric oxide. by internal combustion engines.

Further. objectsand advantages will become more fully apparent in the subsequent description in the specification.

In the drawings:

.FIG'.. 1 is afragmentary, section of an. internal. combustionw engine provided. with a carburetor and intake airrcleaner illustrative of structure suitabletothe practice. ofsthepresent invention.

FIG..,2 is a vertical section taken, on line 2-.2:.of FIG. 1.

TFIG; 3- isa'. perspectivewview of a diametrically sectionedjnmaterialtray utilized: in .the air. cleaner insthe practice. ofjthe present invention.

FIG; 4 isxa section taken on line 4-4 of: EIG.:3 but showing-air treating materials in the tray.

"FIG; 51=is2 a fragmentary view oiian internal combustion engine-showing an intake manifold; air cleaner, and carburetor thereof'as well as a fragmentary portion-of an enclosing .housing. for the engine-with a further form of air, preconditioning. apparatus suitable forthe practice of the present invention.

TFIG'. 6. is. a section taken, on .line 66 of'FIGJS showingthe-internal structure of'the air preconditioning apparatus of FIG. 5.

FIG; 7 is a section of the air preconditioning apparaatent tus of FIG. 5 taken at a. position represented by line 7-7 in FIG. 6.

Referringin greater detail to the drawings:

Referring to FIG. 1, an internal combustion engine is fragmentarily represented at 10 having a combustion chamber '11, an intake manifold 12, a carburetor 13, and an air cleaner '14. A spark plug 15 serves the usual purpose of igniting fuel in the presence of air while under compression in the combustion chamber 11. The elements as shown-in FIG. 1 are conventional but, as illustrated in FIGS. 2 and 3, the internal construction of the air cleaner 14 is modified. so as to practice the process of the present invention.

As fragmentarily shown in FIG. 2 the carburetor 13 provides an upwardly extended intake conduit 20. The air cleaner- 14 has a sleeve 21 which slides downwardly over the upper end of the conduit 20 and is clamped thereon by a circumscribing collar 22 constricted by a bolt 23 in the well known manner. The cleaner 14 provides an annular housing 24 having a bottom wall welded or otherwise. secured to the sleeve 21 in fluidtight connection and an upwardly extended substantially cylindrical wall. An inner cylindrical wall 25 is supported concentrically on the outer wall of the housing 24 by brackets 26 inwardly extended from the outer wall of the housing in downwardly spaced relation to the upper edge thereof. As shown, the inner wall 25 extends. upwardly an appreciable distance from the upper edge of .the outer wall. A substantially cylindrical grill 27 is slidably fitted downwardly within the outer wall. of the housing24 and rests on the brackets 26. The grill hasperforations 28 for the admission of air. A cover 29 is fitted downwardly against the upper edges of the grill 27 and inner wall 25 in substantially air-tight engagement therewith. To hold the cover in position, a spider 30 is provided in the sleeve 21 and has anut 31 secured centrally thereof in alignment with an opening 32 therethrough. A bolt 33 having a wing nut 34 integral. therewith is extended downwardly through an opening 35 in the cover and screw-threadably engaged in the nut 31. It will be readily understood that the cover can be tightened into. place by tightening the bolt 33 or removed by first removing the bolt.

It will be observed in FIG. 2 that the grill 27, inner wall. 25,. and cover 29 define a filter compartment 40. To provide a floor for the compartment, an annular plate 41 is rested on the brackets 26 and fitted between the grill 27 and. inner wall 25. In inwardly spaced relation to the grill, the floor plate is provided with air passagesv 42 downwardly disposed from the filter compartment. The compartment is filled with any suitable air filtering material 43, such assteel wool, fiber, or the like.

-It-.will be noted that the inner wall 25 terminates short of'the bottom of the housing 24 and that a pool of oil 50 is preferably provided in the bottom of the housing in downwardly adjacent spaced relation to the inner wall.

The spacing of the inner wall 25 from the sleeve 21 provides an air passage 55 therebetween. This passage is upwardly extended by a sleeve extension 56 of reduced diameter providing a shoulder 57. An annular bracket 58 is secured to the inner wall 25 in. horizontal alignment with the shoulder 57. A series of trays 59 are rested in stacked relation on the shoulder 57 and bracket 58 in slidably fitted relation between the inner wall 25 and the sleeve extension 56.

The trays are conveniently of identical form and, as shown in FIG. 3, may be stamped from sheet metal or other sheet material. to provide a perforate bottom 62 having concentric upstanding inner and outer walls 63 and 64, respectively. Although three trays. are shown as utilized in FIG. 2, any desired number thereof may be an ployed. The bottom of each tray is covered with granular particles of copper 65 of a size such that they do not pass through the perforations in the bottom 62. It is to be understood that when the term granular is employed it is intended to encompass shavings, threads, filaments, and other physical forms providing extensive surface area in relation to the total mass of copper utilized. The copper particles in each of the trays are intimately contacted with particles or powder of a solid material or materials selected from the solid acids and the acid forming solid salts. For example, solid acids such as tartaric, C H O dextrotartaric; dihydroxysuccinic; citric, C H O malic, C H O succinic, C H O sulfonic, --SO H or -SO H; and the like are excellently suited to the purpose. The acid forming salts of suitable solid form are typified by sodium bisulfite, NaHSO potassium bisulfite KHSO sodium sulfite, Na SO potassium metabisulfite, K S O ammonium nitrate, NH NO chromic oxide, Cr O ammonium chloride, NH Cl; aluminum chloride, AlCl and the like. The solid acid material or acid forming solid salt material is indicated at 66 in FIGS. 2 and 4. The copper 65 and material 66 in the trays 59 must possess sufiicient porosity for the passage of air therethrough and the material 66 should have a sufiicient affinity for water that slight amounts of water vapor in the air will gradually ionize such material for interaction with the copper. In dry climates, the afiinity of the materials for water may be enhanced by the addition of small amounts of sodium chloride, not shown, or other water attracting material. Although any one of the acids or salts described may be employed with the copper, greater accommodation to varied environmental conditions and moisture in the atmosphere can be attained by the use of several such materials. For example, the utilization of tartaric acid in the bottom tray, aluminum chloride in the second tray, and ammonium chloride in the third tray have been found excellently suited for the purpose, The copper reacts with the solid materials in proportion to their respective molecular weights and the quantities thereof are preferably employed in such proportion.

In FIG. 5, an internal combustion engine is fragmentarily indicated at 70 having an intake manifold 71 mounting a carburetor 72 having an air filter 73. The housing for the engine includes a dash panel 74 which mounts a housing 75. The housing is closed except for air intake openings 76 adjacent to the bottom of a side wall thereof. The housing 75 conveniently has a removable lid 77 for assembly and service convenience. An air duct 78 extends from the upper portion of the housing 75 and connects to the intake manifold 71.

As best shown in FIGS. 6 and 7, a plurality of trays 80 are arranged in stacked relation in the housing. Each tray has a spacing flange 81 endwardly directed therefrom and air passages 82 in its end adjacent to, and below, the flange. Each tray is also open at the top. Filter material 83 is placed in the housing 75 over the intake opening 76. The bottom tray is rested in the bottom of the housing with its flange 81 overlaying the filter material. A second tray 86 is rested on the lowermost tray and has its flange 81 oppositely disposed from that of the first tray. Successive superimposed trays have their flanges alternately extended so that the assembly provides an air conduit inwardly through the openings 76, through the filter material 33, longitudinally of the bottom tray, upwardly from the open top of the bottom tray, inwardly through the air passages 82 of the second tray, longitudinally of the second tray and upwardly and into the air passages 82 of the third tray and so on through each tray and subsequently out of the housing 75 through the duct 78 to the intake manifold 46.

As described in connection with FIG. 4, a layer of copper particles 65 are provided in each of the trays and intimately contacted with a solid acid material or acid forming solid salt 66.

Operation The operation of the structures described in the Practice of the process of the present invention is believed to be readily apparent and is briefly summarized at thrs point. As the engines 10 and 70 are operated in the usual manner, air is drawn in the intake manifolds 12 and 71 thereof. Referring to FIG. 2, air passes through the perforations 28, is filtered by the material 43, passes downwardly beneath the lower edge of the inner wall 25, where heavy particles borne by the air stream are deposited in the oil 50, and thence passes upwardly through the trays 59, down through the sleeve 21, through the carburetor 13, and into the combustion chamber 11 through the manifold 12.

Referring to FIGS. 6 and 7, the air passes through the intake openings 76, is filtered by the material 83, passes successively through the trays 80, and thence outwardly through the duct 78 into the intake manifold 71 and from there into the combustion chamber, not shown, of the engine 70. In passing through the trays 59 of the form of air preconditioning structure shown in FIGS. 1 through 4 and through the trays 80 of the form of the preconditioning apparatus shown in FIGS. 5 through 7, the air passes through the porous mixed masses consisting of the copper 65 and solid acid or acid producing solid salt material 66. Moisture borne by the air gradually is accumulated by the material which in turn is slowly ionized and reacts with the copper. As a result, a fine powdered cupric salt is produced which is readily air borne in the air stream passing through such masses. For example, when tartaric acid is used at 66, copper tartrate When the copper tartrate burns in the combustion chamberof the engine, copper oxide is formed.

When aluminum chloride is utilized, it disassociates in the presence of moisture to form hydrochloric acid.

The hydrochloric acid reacts with the copper to produce copper chloride. Cu+2HCl- CuCl When ammonium chloride is employed, copper chloride is similarly formed after the disassociation of the ammonium chloride to make hydrochloric acid available.

The chemical interaction of the other solid acids and acid producing solid salts with copper will be readily apparent and are not further described.

The air borne cupric salts (OuC H O QlCl-g, etc.) are then drawn into the combustion chamber of the engine with which the devices are associated, with the usual hydrocarbon fuel and air. The mixture, now being accompanied by the cupric salt, is compressed in the combustion chamber and the mixture ignited. As a result the cupric salt is oxidized to provide the copper oxide which in turn acts as an efiective catalyst for combustion of thehydrocarbon fuel. Only minute quantities of copper oxide need be present to attain the described catalytic action.

The copper oxide introduced in the manner described tends to deposit onthe electrodes of the spark plugs em ployed and to continue its effect. For example, the eight spark plugs of a 1959 automobile ofpopular make driven for 4,560 miles under the practice of the present invention as described, had an aggregate deposit of 37.0 micrograms of copper oxide. Similarly, laboratory tests of the copper oxide deposits on the spark plugs of three other automotive engines operated under the process of the present invention for various periods showeddeposits of copper oxide on the eight spark plugs of each engine of 3.0 micrograms, 2.3 micrograms, and 4.8 micrograms,

respectively. The presence of the copper-oxide attains a more thorough combustion of the fuel and is even effective in insuring combustion of the olefins and higher hydrocarbons. Further, its presence is conductive to the reduction of the nitric oxide, normally found in the exhaust of internal combustion engines, to nitrogen and oxygen so as to avoid the smog producing effect of nitric oxide.

In a test conducted by an independent scientific laboratory, the structure shown in FIGS. 5, 6, and 7 was connected, also as shown, to the internal combustion engine of a 1959 automobile of popular make. The trays contained particles of copper intimately contacted by tartaric acid, aluminum chloride, and ammonium chloride respectively. The engine was operated at 1,000 r,.p.m.-and tests conducted after the engine had reached operating temperature. The exhaust gases were then tested by infrared Comparative values in mole percent Total hydrocarbons Carbon Ethylene Acetylene Methane (C; and monoxide higher) Condition A- 0. 009 0.67 0.03 0.05 Condition B. 0. 024. 6+ 0. 09 1.03 Present.

These results typify various test results attained by the process of the present invention and clearly reveal improved combustion and virtual elimination of carbon monoxide.

In many instances the process of the present invention has been found to reduce the carbon monoxide content of exhaust gases of internal combustion engines by as much as 90% and unburned constituents by as much as 60%. The process is effective in facilitating the combustion of olefins and the higher hydrocarbons contained in hydrocarbon fuel as well as in the minimizing of the exhaust of nitric oxide.

Although the invention has been herein shown and described in what is conceived to be the most practical and preferred method and embodiment, it is recognized that departures may be made therefrom within the scope of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent methods, devices and apparatus.

Having described our invention, what we claim as new and desire to secure by Letters Patent is:

1. In the operation of an internal combustion engine having a combustion chamber, the steps of introducing a powdered cupric salt into the combustion chamber with hydrocarbon fuel and air of combustion, and oxidizing the fuel and the cupric salt in the combustion chamber whereby the latter forms copper oxide which acts as a catalyst in the oxidation of the fuel.

2. A process for improving the combustion of hydrocarbon fuels containing olefins and higher hydrocarbons in internal combustion engines having combustion chambers comprising introducing a powdered cupric tartrate in air stream with said fuel into the combustion chamber, and igniting the fuel in the combustion chamber in the presence of the cupric tartrate whereby copper oxide is formed by decomposition of the cupric tartrate and acts as a catalyst in the oxidation of the olefins and higher hydrocarbons.

3. A process for improving the combustion of hydro carbon fuels containing olefins and higher hydrocarbons in internal combustion engines having combustion chambers comprising introducing a powdered cupric chloride in air stream with said fuel into the combustion chamber, and igniting the fuel in the combustion chamber in the presence of the cupric chloride whereby copper oxide is formed by oxidation of the cupric chloride and said cop per oxide acts as a catalyst in the oxidation of the olefins and higher hydrocarbons.

4. In the operation of an internal combustion engine having a combustion chamber, a carburetor having an intake, and an intake manifold interconnecting the carburetor and the combustion chamber and through which hydrocarbon fuels are drawn from the carburetor into the combustion chamber; the step of introducing a powdered cupric tartrate in air stream into the intake of-the carburetor for passage through the manifold with the fuel into the combustion chamber.

5.'In the operation of an internal combustion engine having a combustion chamber, a carburetor having anintake, and an intake manifold interconnecting the carbu retor and the combustion chamber and through which hydrocarbon fuels are drawn from thecarburetor into the combustion chamber and through which air is drawn through the intake of the carburetor; a process for em hancing the combustion of the fuel and minimizing the presence of nitric oxide and carbon monoxide in the end product following combustion of the fuel comprising passing atmospheric air over copper in the presence: of a solid material having an acid reaction in the presence of moisture gradually ionizing the solid material with moisture from the air to interact with the copper to form a powdered copper salt, directing said air and the copper salt into the intake of the carburetor where it is mixed with the fuel, and burning the fuel in the combustion chamber in the presence of the copper salt whereby the copper salt is transformed into copper oxide which acts as a catalyst in the oxidation of the fuels and carbon monoxide as well as in the reduction of the nitric oxide.

6. A process for preconditioning air for use in internal combustion engines having combustion chambers comprising passing a stream of air over granular copper particles which are contacted by a solid material having an acid reaction in the presence of moisture, gradually ionizing said solid material by the application of air borne moisture thereto whereby said solid material and the copper particles react to form a copper salt, directing the copper salt in the air stream passed over the copper particles into the combustion chamber of an internal combustion engine, and oxidizing the copper salt in the combustion chamber to copper oxide for use as a catalyst for combustion of hydrocarbon fuels in the combustion chamber.

7. The process of claim 6 in which said solid material is solid acid material in granular form.

8. The process of claim 6 in which said solid material is a solid acid forming salt in granular form.

9. The process of claim 6 in which said solid material is tartaric acid in granular form.

10. The process of claim 6 in which said solid material is ammonium chloride in granular form.

11. The process of claim 6 in which the solid material is aluminum chloride in granular form.

12. A process for preconditioning atmospheric air for use in internal combustion engines comprising passing an air stream successively through a mixture of granular copper particles and tartaric acid, granular copper particles and ammonium chloride, and granular copper particles and aluminum chloride, said air stream containing sufiicient moisture gradually to ionize the tartaric acid, the ammonium chloride and the aluminum chloride for interaction with the copper particles of their respective mixtures to produce powdered cupric tartrate and powdered cupric chloride; and carrying said powdered cupric tartrate and'cupric chloride in air stream from their respective mixtures for use in internal combustion engines. 13. In an internal combustion engine having an inlet air supply, means for improving combustion in the engine comprising granular copper particles, a solid salt material in intimate contact with the copper particles, said copper particles and salt being of a character adapted to interact in the presence of moisture to form a cupric tartrate compound, and means for positioning said compound in the inlet air supply of the engine.

14. In an internal combustion engine having an inlet air supply, means for improving combustion in the engine comprising granular copper particles, a solid salt material in intimate contact with the copper particles, said copper particles and salt being adapted to interact in the presence of moisture to form a cupric tartrate compound, and an air pervious tray positioning said compound in the inlet air supply of the engine whereby the inlet air supply carries particles of said compound into the engine.

15. In an internal combustion engine having an intake manifold, an intake conduit upwardly extended from the manifold, and filtering means having inlet and outlet openings releasably mounted on said conduit in circumscribing relation thereto; a plurality of air pervious members disposed within said filtering means between the inlet and outlet openings, and a cupric tartrate compound disposed in said air pervious members whereby air moving through the filtering means passes through said compound.

l6. In an internal combustion engine having an intake manifold, an intake conduit upwardly extended from the manifold and providing an opening for the entrance of air into said manifold, an air filter having inlet and outlet openings, a hollow tube forming said outer opening having opposite ends, one of said ends being releasably fitted about said intake conduit, and the other end terminating within the filter, a plurality of circular air pervious trays secured to said end of the tube within the filter in circumscribing relation thereto, and a granular cupric tartrate compound disposed in said trays and through which air passing from the inlet of the filter to the outlet is directed during engine operation whereby particles of said compound are carried into the engine for improving combustion.

References Cited in the file of this patent UNITED STATES PATENTS 2,086,775 Lyons et al. July 13, 1937 2,197,498 Guthmann Apr. 16, 1940 2,460,700 Lyons Feb. 1, 1949 2,477,098 Taylor et al. July 26, 1949 7 2,552,555 Houdry May 15, 1951 2,839,037 McKeever' June 17, 1958 

1. IN THE OPERATION OF AN INTERNAL COMBUSTION ENGINE HAVING A COMBUSTION CHAMBER, THE STEPS OF INTRODUCING A POWDERED CUPRIC SALT INTO THE COMBUSTION CHAMBER WITH FUEL AND THE CUPRIC SALT IN THE COMBUSTION CHAMBER WHEREBY THE LATTER FORMS COPPER OXIDE WHICH ACTS AS A CATALYST IN THE OXIDATION OF THE FUEL. 